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Energy 28 (2003) 575589 www.elsevier.com/locate/energy

Evaluation of the 200 MWe Tonghae CFB boilerperformance with cyclone modification

Jong-Min Lee , Jae-Sung Kim, Jong-Jin Kim

Advanced Power Generation & Combustion Group, Power Generation Laboratory, Korea Electric Power Research

Institute, Korea Electric Power Corporation, 103-16 Munji-dong, Yusung-gu, TaeJon 305-380, South Korea

Received 21 February 2001

Abstract

The performance of the Tonghae CFB boiler with modification of the cyclone has been evaluated usingthe IEA-CFBC model. The effect of the cyclone efficiency on solid hold-up and pressure and temperatureprofiles in the combustor has been determined. From the calculated results, solid hold up in the lean phaseof the combustor and pressure in the combustor increase, whereas solid hold-up in the dense phase andtemperature in the combustor decrease as the cyclone efficiency increases. After modification of the cyclone

through extension of the vortex finder and reduction of the width of the cyclone inlet duct, Pupper part andPlower part in the combustor increase from 1328 to 1942 Pa and from 4402 to 4950 Pa, respectively. Thetemperature and the emission of SO2 of the combustor decrease after modification of the cyclone. Therefore,modification of the cyclone to improve its efficiency can allow operation and control of the Tonghae CFBboiler to be stable. The simulation results by the IEA-CFBC model can also explain well the improvedperformance of the CFB boiler. 2003 Elsevier Science Ltd. All rights reserved.

1. Introduction

The design engineering and construction project of the Tonghae thermal power plant CFBboiler (2 units), located in Tonghae, Korea, was begun by the Korea Electric Power Corporation(KEPCO) in early 1993. Combustion Engineering Inc. (ABB-CE) has designed a 200 MWe CFB,firing Korean anthracite fuel [1]. In this project, KOPEC (Korea Power Engineering Company)served as the project architectural engineering firm and is responsible for various other plant

Corresponding author. Tel.: +82-42-865-5362; fax: +82-42-865-5374. E-mail address: [email protected] (J.M. Lee).

0360-5442/03/$ - see front matter 2003 Elsevier Science Ltd. All rights reserved.doi:10.1016/S0360-5442(02)00155-X

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576 J.-M. Lee et al. / Energy 28 (2003) 575589

system designs and equipment procurement. Additionally, HANJUNG, which is one of the heavyindustry companies in Korea, is responsible for the boiler equipment fabrication and procurement.

The Tonghae thermal power plant, firing domestic anthracite, is different from recent Koreanpower plants. It was selected over the conventional pulverized coal boiler because of its improvedefficiency of burning low-quality fuels and its improved emissions capability. The two 200 MWeunits of the Tonghae thermal power plant had been designed in such a manner that they couldoperate more efficiently and meet the Korean environmental standards without external environ-mental control systems. Also, they would not need to fire supplemental fuel oil during normaloperation, though all pulverized coal boilers in Korea should use fuel oil to burn Korean anthracite.

The CFB unit 1 and unit 2 have been operated commercially since October 1998 and October1999, respectively. The initial operation period of unit 1, in 1998, clearly demonstrated that fullload operation was successful [2]. However, there was apparently some room for optimization,particularly regarding the temperatures of the furnace and cyclones/sealpots and the emission of

SOx that were somewhat higher than expected. It was difficult to maintain stable operation dueto the formation of clinker for high temperatures in the cyclones/sealpots. Therefore, modificationof the cyclone to improve its efficiency was accomplished through extension of the vortex finderand reduction of the width of the cyclone inlet duct. This modification improved the performanceby lowering the temperature and SOx emissions through an increase in the solid circulation rate.

This paper gives a description of the status of the Tonghae CFB boiler after cyclone modifi-cation with the simulation results by the IEA-CFBC model in which the effect of cycloneefficiency on the performance of the CFB has been determined.

2. IEA-CFBC model

Many models of the CFBC have been developed since the early 1990s, based on the comprehen-sive bubbling fluidized bed combustion model. In the CFBC modeling approaches, there are differ-ent types of model, which can be distinguished as the global model, the one-dimensional model(only gradients in vertical direction were considered), the 1.5-dimensional model (a lateral distinc-tion between core and annulus was considered) and the multi-dimensional model (computationalfluid dynamics). The multi-dimensional model, which is in progress, is still far from mature

because access to sufficient computational power, adequate for solution of the model, is limitingthe use of CFD codes [3,4]. However, much work has been done, and some results have beenapplied to industrial CFB plants by modeling the CFBC with the one- and 1.5-dimensional models[5,6]. Of these models, the IEA-CFBC model, developed by the mathematical modeling group inthe IEA (International Energy Agency), offers a good approach for comprehensive and suitablemodeling. Also, it has been applied to several industrial CFB plants and has shown good accuracyfor prediction of the performance of CFB plants [7,8]. The IEA-CFBC model consists of severalfields of mechanical, chemical and thermal processes, which are dependent on each other duringthe CFBC processes. The overview of the processes of this model was well presented in previousstudies [7,9].

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3. Tonghae CFB boiler features

3.1. CFB boiler features

The Tonghae CFB combustor is shown in Fig. 1(a). It consists of parts of feeding coal andlimestone, primary air (PA), secondary air (SA) and fluidizing air (FA) suppliers, the main com-bustion part (furnace, cyclones, sealpots), a FBHE (external Fluidized Bed Heat Exchanger), aFBAC (Fluidized Bed Ash Cooler) and backpass. The combustor (19 m (W)7 m (L)32 m (H))has a rectangular footprint and is significantly wider than it is deep, incorporating an aspect ratioof more than 2:1. The lower section (to about 7 m from the distributor) of the combustor istapered and is covered with an erosion resistant plastic refractory material. As all the fuel feedpoints are along the combustor front wall, the rectangular geometry was chosen to allow for good

fuel mixing. Fuel is introduced into the combustor at six locations along the front wall. Limestoneis injected with the fuel in two injection ports along the rear wall. PA is introduced to the combus-tor via the fluidizing air grate. The grate is comprised of T-style fluidizing nozzles patented byABB-CE. The T-style fluidizing nozzles include relatively large openings to reduce the potentialof plugging associated with many nozzle designs while maintaining a pressure drop to precludebacksifting. The T-style fluidizing nozzles are employed in the fluid bed heat exchangers as wellas in the sealpots. SA is introduced at the lower combustor along the front and rear walls andinto the four start-up burners. Bottom ash is removed from the bottom of the combustor via twoash control valves (ACV) and is introduced into a FBAC, which contains an economizer andcooling water heat transfer surface. Heated fluidizing air is returned from the FBAC vents intothe combustor at four locations along the front wall. Three refractory lined steel plate cyclonesare fitted to receive the flue gas and solids mixture from the combustor. The cyclone dimensionsbefore and after modification are shown in Fig. 1(b). The sealpots serve to create a pressure sealfrom the positive pressure in the combustor to the negative pressure in the cyclone. This pressureseal prevents the flow of material back up the cyclone from the bottom of the combustor. Thesealpot is a compact, low-velocity multi-chamber fluidization grate. In the Tonghae CFB unit, theboiler turndown requirement, coupled with the difficult to burn anthracite fuel, resulted in FBHEs.At each of the three sealpots, a stream of the solid materials is diverted and introduced into aFBHE. The FBHEs are bubbling beds, containing natural circulation evaporative, superheat andreheat heat transfer surfaces. As the solids from the sealpots flow over and through the FBHEheat transfer surfaces, the ash is cooled and then returned to the combustor.

3.2. Properties of coal and limestone

Korean anthracite contains 39% ash, 4% VM (volatile matter), 53.7% FC (fixed carbon) and3.3% moisture. The coal contains low S (0.6%) and N (0.2%) and has a relatively low heatingvalue (4600 kcal/kg). The fraction of coal in the size range of 0.16 mm is over 95% on thedesign basis. Limestone contains 90% CaCO3 and 4.2% MgCO3, and all particles are smallerthan 1.0 mm (0.7 mm95%, 0.5 mm90%). The proximate and ultimate analyses and theparticle size distribution of the coal and the limestone are shown in Tables 1 and 2, respectively.

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Fig. 1. (a) Schematic of the Tonghae CFB boiler and (b) dimensions of the cyclone.

3.3. Operating conditions and modeling of the CFB boiler

The operation conditions with the variations of load are shown in Table 3. The ratio of primaryair to secondary air supplied to the CFB combustor is from 0.62 to 0.73. Coal flow rate changes

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Table 1

Analyses of coal used in the Tonghae CFB boiler

Proximate analysis wt.% Ultimate analysis wt% (dry basis)

C 54.7

Moisture 3.3 H 0.3

Volatile matters 4.0 O 3.8

Fixed carbon 53.7 N 0.2

Ash 39.0 S 0.6

Heating value (dry basis) 4600 (kcal/kg) Ash 40.4

Table 2

Particle size distribution of the coal and the limestone

Range (mm) Coal (wt%) Limestone (wt%)

5.6 0 0

4.755.6 1.0 02.84.75 2.0 022.8 16.0 01.02.0 31.0 10.61.0 16.0 160.250.6 17.0 410.10.25 10.0 170.0750.1 2.0 150.075 5.0 10

Table 3

Operation conditions with different load

#a Combustor height (m) Additional air flow rate (m3/s)

100% load 75% load 50% load 30% load

1 0.0 87.22 76.3 65.58 68.34

2 0.43 10.26 4.4 4.4 4.4

3 1.37 0.93 0.93 0.93 0.93

4 1.70 9.14 9.14 9.14 7.34

5 2.44 18.94 14.54 14.54 14.54

6 4.48 23.09 9.9 9.9 9.9

7 28.53 (32.9) 0 0 0 0

8 Coal (kg/s) 27.3 20.7 14.5 7.9

9 Lime (kg/s) 0.83 0.63 0.44 0.38

a Air inlet position: 1, PA; 2, SA (four-injector); 3, feeder (coal and limestone) transport air; 4, sealpot+FBHE return

air; 5, SA(three-injector); 6, SA (nine-injector); 7, exit (top of combustor); 8, 9, coal and limestone feed rate.

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from 7.9 to 27.3 kg/s and the ratio of limestone to coal flow rate is from 0.03 to 0.046 with thevariations of load. To compare the calculation data with the measured data for the CFB boiler,temperature and pressure profiles, particle size distribution, flue gases concentration and theamount of fly and bottom ash were measured during the operation of the CFB boiler. Pressurealong the combustor was measured at 0.9, 5.2 and 28.5 m above the distributor. Total pressure,including pressure drop of the distributor, was also measured by a pressure transmitter installedat the windbox. Temperature measuring points along the combustor were selected at 0.75 and5.65 m from the distributor and at the three cyclone inlet ducts. In each point in the combustor,six different horizontal temperatures were measured. Measurement of particle size distribution wasachieved by sampling from the backpass and electric precipitator (filter ash), FBHE (recirculatingparticles) and FBAC (overflow particles). However, since the Tonghae CFB boiler is a commercialone for the generation of electricity, the measurements were restricted to its operation point. Inorder to measure the reliable data from the CFB boiler, all measurements were taken for 6 months

and the average data values were used in this study.The sequence of calculation in the model study is as follows [7,9,10]:

1. After initialization of the riser geometry, the gas and solid properties and the fluid dynamicfundamentals are calculated. The input values are based on Tables 13. Other important valuesused in this model are shown in Table 4.

2. A preliminary balance of fuel and air is performed.3. After initial pre-balancing of an average size distribution function for estimation of the circu-

lation rate, cyclone load and dense bed height, the real particle size distribution is balancedfor each material such as coal, char and limestone.

4. Reactions such as dry, devolatilization, combustion and sulphur capture are linked to the particle

phase and catalytic particle surfaces, where oxygen consumption and release of combustionproducts are also calculated and further reactions of the gas products are calculated in thegas phase.

5. The balances of solid and gas species concentration are solved independently, and both massbalances are adjusted in an iteration loop.

6. The energy released by the reactions with the heat flow and the heat transfer is balanced to

Table 4

Input data for the Tonghae CFB boiler modeled

Parameters Coal Char Limestone

Density (kg/m3) 2200 1710 2600

Sphericity [12] 0.71 0.71 0.71

Heat capacity (J/kg K) 840 600 840

Attrition constant [13] (1/m) 1.0106 2.8105 1.0106

Fragmentation constant [14] 1.0 1.0 1.0

Pre-exponential factor [15] (kg/m2 s Pa) 0.79 Activation energy, E/R [15] (K) 19,000 Sulphation constant [16] (m/s) 0.15Decay constant [17], au (1/s) 5.5 5.5 5.5

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yield the temperature profile in the riser. The feedback of the temperature to the reaction rateis considered in an iteration loop.

7. Pollutants are calculated in a post process, to avoid solution of all kinetic equations inside theiteration loops.

4. Results and discussion

4.1. Variation of the CFB performance with cyclone modification

The effects of the cyclone efficiency and cyclone modification on the performance of theTonghae CFB were determined by using the IEA-CFBC model. The overall separation efficiencyof the cyclone is defined as the summation of the entrance efficiency and single particle efficiency

[7]. The saturation carrying capacity, which is related to the entrance efficiency, can be adjustedby changing the cyclone entrance efficiency coefficient and acceleration coefficient in the model.

The predicted results of the axial solid hold up and the pressure profile in the combustor withvariation of the cyclone efficiency are shown in Fig. 2(a) and (b), respectively. The solid holdup in the dense phase gradually decreased (0.1870.059) with increasing cyclone efficiency,whereas it increased (0.0050.014) in the lean phase. The dense bed height also increased. Thisis because the fraction of fine particles, which can be captured by the cyclone and circulated,increases in the total bed material. As depicted in Fig. 2(b), this solid hold up variation affectedthe pressure profile. The differential pressure, as well as temperature, in the CFB combustor,which can be obtained as practical operation data, is important to analyze and control the operatingcondition. During the operation of the CFB combustor,Pupper part (Pupper part P2 P1) regardedas the basis of completion of solid circulation, was 1328 Pa (standard deviation, SD 156.5,standard error, SE 24.4) and Plower part (Plower part P3 P1) was 4402 Pa (SD 326.5,SE 50.9) at 100% load before modification. So, the cyclone efficiency can be considered asabout 98.7% from these data, which could also be determined from the data of temperature pro-files, fly/bottom ash ratios and particle size distributions. The differential pressures in the densephase and lean phase showed the same tendency of solid hold up variation.

The calculated temperature in the dense phase, as shown in Fig. 3, was almost the same vari-ation with cyclone efficiency, whereas the temperature decreased gradually in the lean phase. Thetemperature of the annular wall layer was lower than that of the core region and also decreasedwith increasing cyclone efficiency because the particles were in contact with the membrane walls

and flow down into the dense phase. The cyclone inlet temperature (symbol) was measured some-what higher because of the low solid circulation rate and low combustion reactivity of the Koreananthracite. From this, an improvement of cyclone efficiency is expected to allow the temperature,especially in the cyclone and sealpots, to be lower.

The calculated particle size distribution in the overflow, bed content, recirculation and bag filterappeared to include more fine particles with increasing cyclone efficiency. The calculated resultsappeared to be fitted well by the samples taken from the boiler. The cyclone efficiency, whichdid not show a significant difference at 98.7%, could also be estimated by comparing the calcu-lated and sampled data. The calculated discharge rate of bottom ash increased, whereas that offly ash from the bag filter (backpass and electric precipitator) decreased with increasing cyclone

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Fig. 2. Axial solid hold up (a) and pressure (b) profiles with variation of cyclone efficiency.

efficiency. The calculated ratio of bottom to fly ash was about 4:6 at 98.7% cyclone efficiency,and this value showed reasonable agreement with the measured values, which are about 410 ton-bottom ash/day and 630 ton-fly ash/day, from the boiler before cyclone modification.

As the cyclone efficiency increased, the model calculations predicted higher emissions of CO,

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Fig. 3. Axial temperature profile with cyclone efficiency in the combustor (line: calculated value, symbol: measuredvalue).

O2 and NOx and lower emissions of CO2 and SO2. The higher emission of CO may be causedby the increase in the circulated fine particles, including unburned carbon, as reported previously[10]. The lower SO2 emission was because of the increase in circulated limestone particles andthe decrease in the freeboard temperature with increasing cyclone efficiency. In addition, thecalculated SO2 emission with increasing Ca/S mole ratio (1.53.0) changed from 300 to 150 ppmat a cyclone efficiency of 98.7%. These values corresponded to the measured SO2 emissions. Inthe model calculation, the increase in Ca/S mole ratio appeared to be limited in reducing the SO2emission, so it was necessary to improve the cyclone efficiency to enhance the SO2 captureefficiency.

The effects of modification of the cyclone on the performance of the CFB boiler are shown inFig. 4(a) and (b). With increasing the length of the vortex finder, the cyclone separation diameter

and the discharge rate of the fly ash decreased, and the solid circulation rate increased, as shownin Fig. 4(a). The predicted results showed a performance improvement of about 1020% as thelength of the vortex finder was increased by 1 m. With reducing the cyclone inlet duct throughdecreasing its width, the model results had the same tendency, but the improvement in perform-ance was not appreciable, as shown in Fig. 4(b). Therefore, modification of the cyclone throughextension of the vortex finder was more effective. The model calculation for modification of thecyclone also predicted lower temperature and lower SO2 emissions in the combustor and showedsignificant effects. Consequently, the variation of cyclone efficiency had a great influence on theperformance of the CFB boiler. To achieve stable operation and control of the CFB, it was neces-sary to modify the cyclone geometry as well as optimize the units.

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Fig. 4. Effects of the modification of the cyclone on the performance of the CFB boiler (a) with modification of thevortex finder and (b) with modification of the inlet duct.

4.2. Improved CFB performance after cyclone modification

After modification of the cyclone, which was made through increasing the length of the vortexfinder about 0.9 m and reducing the width of the cyclone inlet duct about 0.2 m, the differential

pressure of the upper part, Pupper part, in the combustor was about 1942 Pa (SD 143.4,SE 22.4). It was higher than the unmodified case (1328 Pa). The differential pressure of thelower part also increased from 4402 to 4950 Pa (SD 313.9, SE 49.0). These were the resultsfrom the changes of the solid hold up in the combustor due to the increase in cyclone efficiency.The calculated results of the axial solid hold up and the pressure profiles before and after modifi-cation of the cyclones are shown in Fig. 5(a) and (b), respectively. The solid hold up in the densephase decreased, whereas it increased in the lean phase after modification. These effects arebecause the fraction of fine particles, which can be captured by the cyclone and circulated,increased in the total bed material. The increases of solid circulation rate and solid hold up inthe lean phase can be estimated from the increase in the differential pressure. In the model calcu-

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Fig. 5. Axial solid hold up (a) and pressure profiles (b) in the Tonghae CFB combustor before and after modificationof the cyclone.

lation for the solid hold up and the pressure profiles in the combustor, the predicted results forbefore and after cyclone modification had good fits.

The temperature profiles before and after modification are shown in Fig. 6 with the predictedresults. The temperature in the combustor, after modification of the cyclone, became lower (866C with SD 15.2 and SE 1.9) than that before modification (896 C with SD 21.7 andSE 1.4). The cyclone inlet temperature (924 C with SD 12.0 and SE 1.1), as well as thesealpots temperature (943 C with SD 15.6 and SE 1.5), also became lower than before dueto the increase in solid circulation rate. Stable operation could be achieved successfully, and thecalculations showed good agreement with the operation results.

The calculated cumulative size fractions of discharged bottom ash, recycle ash and filter ash(backpass and electric precipitator) and samples (symbols) from the field after modification aredepicted in Fig. 7. The calculated results predicted that more smaller particles (100300 m) werecirculated, and the particles in all parts appeared to be smaller after modification of the cyclone.The predicted results also fitted relatively well with the samples from the field.

The predicted gas concentrations in the combustor are shown in Fig. 8(a)(c) with operationresults (symbols) measured from the stack of the CFB. In the calculated results, the concentrationof CO2 increased along the combustor height and increased drastically in the dense region,whereas the O2 concentration showed the reverse tendency as shown in Fig. 8(a). The CO concen-tration increased rapidly in the lower dense region and then drastically decreased with combustor

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Fig. 6. Comparison of temperature profiles before and after modification of the cyclone (line: calculated value, symbol:measured value).

height as shown in Fig. 8(b). From these facts, the combustion reaction was found to be mainlyoccurring in the dense region and to be kept somewhat in the freeboard region. Also, the calculatedconcentrations of CO2 and CO at the combustor exit showed increases of 0.9% and 150 ppm,respectively, after cyclone modification, due to the augmentation of fine coal particles in the bed[11]. However, the measured values of these gaseous concentrations at the stack of the CFB boilerdid not change appreciably. To reduce SO2 emission, it was found necessary to increase the

circulating particles of limestone in the bed material because SO2 was mainly produced in thedense region and was gradually taken up by the entrained limestone particles in the freeboardregion as shown in Fig. 8(c). The calculated and measured SO2 emission after modification becamelower and the sulfur capture efficiency was higher. The reduction in slope of SO2 in the freeboardregion also increased due to increasing the circulating particles of limestone.

The emission of NOx was very low and did not change appreciably before and after modifi-cation of the cyclone because of the relatively low operating temperature in the combustor.

Therefore, the modification of the cyclone to improve separation efficiency allowed the tem-peratures of the furnace and cyclones/sealpots and the emissions of SO2 to be lower and gavemore stable operation.

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Fig. 7. Comparison of particle size distribution before and after modification of the cyclone (line: calculated value,symbol: measured value).

5. Conclusion

During the initial operation period, the Tonghae CFB boiler was demonstrated successfully inspite of some problems, such as a higher temperature profile and higher SO2 emissions thandesired. After modification of the cyclone, based on the simulation results, through extension ofthe vortex finder and reduction of the width of the cyclone inlet duct, Pupper part and Plower partin the combustor increase from 1328 to 1942 Pa and from 4402 to 4950 Pa, respectively. Conse-quently, the temperature and the emission of SO2 of the combustor decrease after modificationof the cyclone, and then stable and improved operation of the Tonghae CFB boiler was achieved.The simulation results by the IEA-CFBC model explain well the performance of the TonghaeCFB combustor with cyclone modification.

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Fig. 8. Gas concentration profiles in the CFB combustor before and after modification of the cyclone. (a) CO2, O2and H2O concentrations, (b) CO concentration and (c) SO2 concentration cyclone (line: calculated value, symbol:

measured value).

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